MTD 2005 800 Series Bedienungsanleitung

Service Manual

2005 800 Series (839) Self Propelled Walk Behind Mower

MTD Products Inc - Product Training and Education Department

FORM NUMBER - 769-02089

10/2005

NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power

equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.

These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperi-

enced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all

instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper-

ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,

although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to

the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these

instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a

product. The company reserves the right to make changes at any time to this publication without prior notice and without

incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations

used in this publication are for reference use only and may not depict actual model and component parts.

Belt Removal ........................................................................................................................ 1

Blade Removal ..................................................................................................................... 2

Transmission/Control Cable Removal .................................................................................. 3

Front Axle ............................................................................................................................. 6

Rear Door ............................................................................................................................. 8

Trail Shield ........................................................................................................................... 9

TABLE OF CONTENTS

SERIES 830 SELF PROPELLED

This is a new series rear wheel drive self-propelled

mowers for 2005-2006 season. These models will be

offered with a Briggs & Stratton engine. The 839E

series comes with the electric start. There are many dif-

ferent adapter plugs to connect to battery pack to the

engines. Units with a Briggs & Stratton engine will use

a 629-04011 stye adapter plug.

629-04011 Adapter

1. BELT REMOVAL

1.1. Disconnect and ground the spark plug wire.

1.2. Drain the fuel tank or place a piece of plastic

under the fuel cap to prevent gas from leaking.

1.3. Position the Mower with the front of the mower

elevated.This will prevent any oil displacement

issue in the engine or transmission. See Figure

1.3.

NOTE: This would be the recommended posi-

tion for most service procedures.

1.4. Remove screw that secures baffle to deck using

3/8 socket. See Figure 1.4.

Figure 1.3

Figure 1.4

Screw Securing baffle to the deck

SERIES 830 SELF PROPELLED

1.5. Remove belt from engine pulley. See Figure 1.5.

1.6. Pushing belt toward the transmission, remove

belt from transmission pulley.

1.7. Pull belt forward though baffle. See Figure 1.7.

NOTE: Belt will fit over blade.

1.8. Install the belt by slipping it over the blade.

1.9. Push the belt though baffle toward transmission

1.10. Slip the belt over the transmission pulley.

NOTE: Pulling the belt forward slightly while slip-

ping the belt over rear belt keepers will help

keep the belt on the pulley.

1.11. Slip the belt over engine pulley. See Figure 1.11.

CAUTION: Check to make certain that the belt is

within the belt keepers.

1.12. Reinstall the screw securing baffle to the deck.

2. BLADE REMOVAL

2.1. Disconnect and ground the spark plug wire.

2.2. Drain the fuel tank or place a piece of plastic

under the fuel cap to prevent gas from leaking.

2.3. Position the mower with the front elevated.

2.4. Secure the blade from rotating.

NOTE: Correct order is as follows:

Starting from the engine and working out:

1) Upper engine pulley

2) Lower engine pulley

3) Engine spacer.

4) Spring washer.890 x 1.70 x.048 - check orientation

5) Flat washer.885 x 1.850 x.060

6) Blade adapter

7) 21” Blade

8) Blade bell support

9) Blade bolt 3/8-24 x 1.50

Figure 1.5

Belt

Figure 1.7

Baffle Belt

Figure 1.11

Belt

Transmission

SERIES 830 SELF PROPELLED

NOTE: Torque is 450-600 inch pounds

3. TRANSMISSION / CONTROL CABLE

REMOVAL

3.1. Disconnect and ground the spark plug wire.

3.2. Drain the fuel tank or place a piece of plastic

under the fuel cap to prevent gas from leaking.

3.3. Remove the small cover from the control hous-

ing using a phillips screwdriver.

3.4. Disconnect the drive cable from the drive control

handle. See Figure 3.4.

3.5. Remove the spring bracket cover.

3.6. Move the height adjuster to the highest position

reducing tension on the height adjuster spring.

Blade stack up

Blade bolt Blade bell support

Blade

Blade adapter

Flat washer

Spring washer

Spacer

Lower engine pulley

Upper engine pulley

Figure 3.4

Drive cable

Drive control handle

3.7. Using some recoil rope or a spring puller CARE-

FULLY disconnect the spring. See Figure 3.7.

3.8. Support the rear of the unit with a 4 x 4 or equiv-

alent.

3.9. Using a 9/16 socket remove the rear wheels.

See Figure 3.9.

Figure 3.7

Height adjuster

spring

Recoil rope

Figure 3.9

4 x 4 Block Rear wheel

SERIES 830 SELF PROPELLED

3.10. Remove the screw and spacer securing cross

bracket to the front and rear height adjusters.

See Figure 3.10.

NOTE: There are left side and right side gears.

• If they are replaced on the wrong side, the drive

to that side will not work.

• Left gears have an “L” stamped on the inside

edge.

• Right gears have a “R” stamped on the inside

edge.

3.11. Clamp a pair of vice grips on the axle near the

transmission case. See Figure 3.11.

3.12. Using a 10MM wrench remove the screw from

each side of the axle. This will allow the removal

of the washer, drive gear, dowel pin, and flat

washer. See Figure 3.12.

NOTE: The drive gears do have an “R” and “L”

on them for side indicators.

3.13. Remove the dust cover.

3.14. Using a 3/8 wrench remove one screw from

each side securing the baffle to the deck.

See Figure 3.14.

Figure 3.10

Screw and Spacer

Figure 3.11

Vice grips

Figure 3.12

Metric Screw

Washer

Drive gear

Dowel

Flat washer

Figure 3.14

Screw securing baffle

SERIES 830 SELF PROPELLED

3.15. Pull off both transmission bearing supports. See

Figure 3.15.

NOTE: Watch for the black spacer located

between the handle bracket and rear the bracket

assembly.

3.16. Remove the rubber grommet that surround the

control cable where it goes though the deck.

See Figure 3.16.

3.17. Elevate the front of the mower.

3.18. Remove the blade as described in the BLADE

REMOVAL section of this manual.

3.19. Remove the belt as described in the BELT

REMOVAL section of this manual.

Figure 3.15

Spacer

Bearing support

Figure 3.16

Rubber grommet

Control cable

3.20. Remove the baffle, transmission and rear deck

assembly all as one piece by tipping out the right

side first then lift left side over the bolt.

See Figure 3.20.

3.21. Pull the cable though deck.

3.22. Slide the rear assembly off the transmission

3.23. Remove the extension spring that connects

transmission to baffle See Figure 3.23.

NOTE: The extension spring can be replaced

without removing the baffle.

Figure 3.20

Baffle

Transmission

Rear deck Assembly

Figure 3.23

Extension spring

SERIES 830 SELF PROPELLED

3.24. Push out the transmission cable bracket.

See Figure 3.24.

3.25. Remove the cable from transmission bracket.

3.26. Remove the transmission from baffle. See Fig-

ure 3.26.

3.27. The cable can be disconnected from the trans-

mission by squeezing the tabs that secure the

cable housing to the bracket.

3.28. Inspect for damaged or worn parts. replace as

need.

NOTE: This producer is necessary to replace

the transmission or the drive cable.

3.29. Assemble mower by reversing the removal pro-

cedures.

NOTE: This is a non-serviceable transmission

the following is done as a professional courtesy

so you may see inside of the transmission.

4. FRONT AXLE

4.1. Remove the spring bracket cover

4.2. CAREFULLY using some recoil rope or a spring

puller disconnect spring. See Figure 4.2.

Figure 3.24

Cable bracket

Figure 3.26

Transmission

Figure 4.2

Spring

Recoil rope

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